Synthetic resin and method of making the same



Patentecl July 25,1933 g uulra 5 m WILLIAM HENRY-mosses CUMBERLAND, MARYLANDseSSIGNOR TO CELANESEjCOR-y roaa rrou OEAMERIGA," or NEW YORK, N; Y., A-GOBIPORATION or DELAWARE SYNTHETIG'RESIN A D: METHOD OF M KmG 'IIj-IE SAME.

Illo Drawing.

Thisinv'ention relates to the preparation of a resin by condensing a ketone'phenol resin with an aldehyde;

' An object of my invention is to produce a synthetic resin of the acetone-phenol type which is of general use but which 1s particularly useful as an ingredient in "varnishes and lacquers because of its waterresistant' oi'ga1iic,si1bstai1ces" witlrphen'ol is heated with approximately another molecular pro portion of fan aldehyde, such as formalde: hyde, a resin 'of'the reactive typeis producedwhich is rapidly converted bysubse quent heating to an infusibleand'insoluble resin.

'Il1ave found that if*ketone-phenolresin such as acetone-phenol-resin '(diphenylol-f propane-acetoneresin) is heated with form aldehyde in the presence of an acid as cat alyst, a condensation takes place to form a new resin having diderent properties from the first. The acetone-phenol resin may be produced by condensing acetonephenol (diphenylol propane) with acetone in the presence of an acid catalyst as is described, in U. S. Patent No. 1,878,249 granted on my copending application No. 227,870 filed October 21, 1927. Throughout this spe'cifi cation the term diphenylol propane is used to denote the product obtained by the condensation of two molecules of phenol with one molecule of acetone and having the empirical formula C I-L 0 and the probable constitutional formula:

The proportion of formaldehyde that is used may be varied, but I have found it preferable to use one gram molecule of forms o'fsthe catalyst used; A

nonsreactive type.

Application filed October 21, 1927. Serial N0. 227,871.

phenol resin (diphenylol-propzine-acetone resin) that is used as the starting material. The acetone-phenol-acetone resin and formaldehyde areheated under reflux together with '01: to -5% of Y a "molecular proportion of an acid, such as hydrochloric acid or phosphoric-acid The resin melts beneath the formaldehyle but does not completely dissolve therein. After some hours of heating, atest of the clear liquid shows that the film'has substantially combined with the resin yielding a. resin which usually appears lighter than that originally used.

The timerequired varies with the temperature employed and the amount and nature The resulting product is washed with Water, and; then distilled ;with -or without steam either at ordinarypressure or under vacuum -.until any; desired freedom. from -un combined u-eactants i of catalyst is obtained. TheresultingrnewwresiniJisof a clear, brown or vdark ;red: color. andumelts at' about 100 C. The resin is of the soluble,fusible and solvents used for making cellulose ester lac-r quers. NVhen-used as anzingrredient 20f cellulosetester lacquershaving cellulose acetate tallic, wood or other smooth hard surfaces and possess a high degree of water resistance. 1

In order to further explain my invention, a specific example of one mode of carrying out the same is here given. The following ingredients K g. Acetone-phenol-acetone resin (diphenylol-propane-acetone resin) 26. 8 Formaldehyde (40% strength) 7.5 Y Phosphoric acid 0. 26

are heated under reflux until substantially all the formaldehyde has combined to form the newjresin. The resin is washed with about 10 kg. of water and then with about 10 kg. of water containing about 1 kg. of sodium carbonate or an equivalent amount of other alkaline material. The resin is then steam distilled or vacuum distilled for about It: is soluble invalcohol, acetone and benzenei:andcv in all. the usual 3 hours, and then furtherdistilled at ordi- As an illustration of the use of the resin in lacquers the following formula-of a lacquer 1s given. i

Cellulose acetate -l, 5. Synthetic resinl n' 5 Softener( such as triacetin) r f 1 Acetone -l 8O Ethyl lactate 20 Obviously other softeners such as diethyl phthalate-may be used instead of the triacetin, and other high boilers may beused instead of ethyl lactate. A p

Itis to be understoodthatthe foregoing detailed description'is given merely by way of illustration and that many variations may be made therein without departingifrom the spirit ofthe invention.

"Having described my invention what I claim and desire to secure by Letters Patent is: I

1.; Process of producing asyntheticresin comprising reacting a crystallizable condensation productof a ketone andphenol with It is very useful as an a ketone in the presence of a condensationpromoting catalyst until condensation takes place and then reacting the resulting resin with an aldehyde in the presence of a condensation promoting catalyst.

" 2. Process ofproducing a synthetic resin comprising reacting a crystallizable condensation product of acetone and phenol with acetone in the presence of a condensation-promoting catalyst until condensation takes place and then reacting the resulting resin with an aldehyde in the presence of a condensation promoting catalyst.

8. Process of producing a synthetic resin comprising reacting a crystallizable condensation product of acetone and phenol with acetone in, the presence of an acid catalyst until condensation takes place and then re acting the resulting resin with formaldehyde in the presence of a condensation'promoting catalyst. 1 a 4. A diphenylolpropane-ketone aldehyde resin substantially identical with that obtained by the condensation of a diphenylolpropane-ketone resin with an aldehyde.

5. A diphenylolpropane-acetone aldehyde resin substantially identical with that obtained by the condensation of a diphenylolpropane-acetone resin Wltllfill aldehyde.

6. A diphenylolpropane-ketone formaldehyde'resin substantially identical with that obtained by the condensation of a diphenylolpropane-ketone resin with formaldehyde.

7,. A diphenylolpropane-acetone formal dehyde resin substantially identical with that obtained by the condensation of a diphenylolpropaneacetone resin with formal dehyde. WILLIAM MOSS. 

